Drywall joint and system and process for making

ABSTRACT

A method of making a drywall joint includes steps of positioning a butt block that has a recessed surface on an interior side of a joint that is to be formed between a first drywall sheet and a second drywall sheet, securing at least one of the first and second drywall sheets to the butt block so that the secured sheet is made to conform in shape to the recessed surface, thereby forming a secondary recess on an exterior of the drywall sheet in the area at which the joint is to be made, and applying joint compound within the secondary recess.

[0001] This is a continuation of U.S. patent application Ser. No.10/144,515, filed May 13, 2002, the entire disclosure of which is herebyincorporated as if set forth fully herein.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates generally to the field of architecture andconstruction. More specifically, this invention relates to the field ofdrywall construction, which is the most common method that is used todayto finish interior walls and ceilings in buildings such as new homes andoffices.

[0004] 2. Description of the Related Technology

[0005] Conventional drywall is fabricated in sheets having a gypsum corethat is contained within a fibrous, cardboard-like outer skin. Drywallsheets typically are approximately four feet in width by eight feet inheight, although this may vary depending upon the manufacturer and thepart of the world in which the product is being used.

[0006] Conventional frame-type construction involves assembling thestructural portion of a wall or ceiling from a framework that isconstructed of a plurality of joists, which are typically 2×4 pieces oflumber. The drywall must be fastened over the framework of joists toform the outer surface of the wall or ceiling. Since a number of drywallsheets will usually have to be applied to a particular wall or ceilingsurface to completely cover the structural framework of the wall or theceiling, the individual sheets of drywall will have to be joinedtogether in a way that is not easily detectable to a viewer after thewall has been finished.

[0007]FIG. 1 depicts a conventional drywall joint 10 that is the mosttypical example of the current state of construction in this area. Asshown in FIG. 1, a first drywall sheet 12 is positioned end-to-end witha second drywall sheet 14, with adjacent edges of the two sheets 12, 14positioned together in a butt-type interface 16. Because of theirregularities that are unavoidable in joist-type construction, it isconsidered preferable to have the butt interfaces 16 between thedifferent sheets of drywall positioned over an open area within thestructural framework, and not directly over one of the joists. Instead,a support member 18 is positioned behind the two drywall sheets 12, 14in order to provide rigidity to the joint and give alignment to thedrywall sheets 12, 14 during the joining process. As FIG. 1 shows, thedrywall sheets are first joined to the support member 18 by a pair ofdrywall screws 20, 22. After the drywall screws 20, 22 have been sosecured, a second pair of screws 24, 26, which are closer to the buttinterface 16, are then inserted and secured between the support member18 and the respective drywall sheets 12, 14.

[0008] At this point, the first and second drywall sheets 12, 14 arejoined together structurally, but are still aesthetically quitedistinguishable. To hide the visible crack of the butt interface 16, alength of adhesive mesh drywall joint tape 28 is applied to the crack atthe butt interface 16, and a substance that is known as joint compound30, or more commonly by the term “mud,” is trowled on top of the tape 28and is spread as smoothly as possible outwardly over the exteriorsurface of the two drywall sheets 12, 14 so as to disguise the joint 10from view as effectively as possible.

[0009] Unfortunately, the added thickness of the joint tape 28 and thejoint compound 30 creates a bulge 32 at the conventional drywall joint10. A skillful contractor will be able to disguise the bulge 32 as wellas it can be disguised, mainly by spreading the joint compound outwardlyfor some distance, but there are some instances in which the bulge 32will remain noticeable, such as when there is overhead spot lightingthat will strike the bulge 32 obliquely, which will tend to make thebold 32 very evident to even the least discerning viewers.

[0010] In addition to the disadvantages of the conventional drywalljoint 10 that are discussed above, it takes a great amount of time andmaterial to smooth the conventional drywall joint 10 when one considersthe number of such joints that will have to be made in the constructionof a large building such as a house.

[0011] A need exists for an improved drywall joint and a system andprocess for making such a joint that will reduce the amount of labor andmaterials necessary to form the joint, and that will enhance theaesthetic value of the finished joint.

SUMMARY OF THE INVENTION

[0012] Accordingly, it is an object of the invention to provide animproved drywall joint and a system and process for making such a jointthat will reduce the amount of labor and materials necessary to form thejoint, and that will enhance the aesthetic value of the finished joint.

[0013] In order to achieve the above and other objects of the invention,a method of making a drywall joint according to a first aspect of theinvention includes steps of positioning a butt block that has a recessedsurface on an interior side of a joint that is to be formed between afirst drywall sheet and a second drywall sheet; securing at least one ofthe first and second drywall sheets to the butt block so that thesecured sheet is made to conform in shape to the recessed surface,thereby forming a secondary recess on an exterior of the drywall sheetin the area at which the joint is to be made; and applying jointcompound within the secondary recess.

[0014] According to a second aspect of the invention, a butt block forforming a drywall joint includes a first surface for engaging a firstsheet of drywall; a second surface for engaging a second sheet ofdrywall; and recess defining structure for defining a recessed areabetween the first and second surfaces, the recess defining structurebeing constructed and arranged to be drawn into contact with butt edgeareas of the first and second sheets of drywall when fully secured tothe sheets of drywall, whereby the butt edge areas will be caused toform a concave secondary recess on an exterior surface of the drywalljoint.

[0015] According to a third aspect of the invention, a drywall jointincludes a first sheet of drywall having a first butt edge; a secondsheet of drywall having a second butt edge, the first and second sheetsof drywall being positioned so that the first butt edge is adjacent tothe second butt edge at a butt interface; recess forming structureengaging the first and second sheets for pulling the first and secondbutt edges inwardly so as to define a secondary recess in exteriorsurfaces of the first and second sheets in the area of the buttinterface; and a sealant applied in the secondary recess.

[0016] These and various other advantages and features of novelty thatcharacterize the invention are pointed out with particularity in theclaims annexed hereto and forming a part hereof. However, for a betterunderstanding of the invention, its advantages, and the objects obtainedby its use, reference should be made to the drawings which form afurther part hereof, and to the accompanying descriptive matter, inwhich there is illustrated and described a preferred embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is a fragmentary cross-sectional view depicting aconventional drywall joint;

[0018]FIG. 2 is a perspective view of a butt block that is constructedaccording to a preferred embodiment of the invention;

[0019]FIG. 3 is a fragmentary cross-sectional view depicting a firstmethod step in a process that is performed according to a preferredembodiment of the invention;

[0020]FIG. 4 is a fragmentary cross-sectional view depicting a secondmethod step in the process that is first shown in FIG. 3; and

[0021]FIG. 5 is a fragmentary cross-sectional view depicting a completedjoint that is constructed according to a preferred embodiment of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0022] Referring now to the drawings, wherein like reference numeralsdesignate corresponding structure throughout the views, and referring inparticular to FIG. 2, a butt block 40 constructed according to apreferred embodiment of the invention includes a first outboard flange42 and a second outboard flange 44. As may be seen in FIG. 2, the firstoutboard flange 42 includes a first surface 46 defined by a forwardportion of the flange 42. The second flange 44 likewise is provided witha second surface 48 on a front portion thereof. The purpose of first andsecond surfaces 46, 48 is to engage the interior surfaces of first andsecond sheets of drywall 12, 14, as will be described in greater detailbelow. The first and second surfaces 46, 48 are substantially planar,and preferably lie within substantially the same plane.

[0023] Referring again to FIG. 2, it will be seen that butt block 40further includes recess defining structure 50 that is embodied as afirst recessed panel 52, and a second recessed panel 54. The recessedpanels 52, 54 are unitary with each other and are joined at a centeraxis 56 that is located at the innermost point of the recess that isdefined by the recess defining structure 50. The first recessed panel 52is unitary with the first flange 42, while the second recessed panel 54is similarly unitary with the second flange 44. The butt block 40 isfabricated from a material that is capable of being penetrated by astandard drywall screw, and that is traditionally capable of enteringsuch screws to the extent necessary to perform the steps that aredescribed with reference to FIGS. 3,4 and 5 below. In the preferredembodiment, this material is fiberglass.

[0024] Referring now to FIG. 3, a method of making an improved drywalljoint according to a preferred embodiment of the invention will now bedescribed. As FIG. 3 shows, the butt block 40 that has been described inreference to FIG. 2 is cut to an appropriate length, and is thenpositioned behind first and second drywall sheets 12, 14 that aredesired to be joined. This is in most cases performed so that the buttblock 40 will be positioned in a void that is defined by adjacent joistswithin a framework for a wall or a ceiling. The butt block 40 ispreferably positioned, as shown in FIG. 3, so that the center axis 56 issubstantially aligned with the butt interface 16 between the edges ofthe drywall sheets 12, 14 that are to be joined. This alignment may beaccomplished by temporarily placing a number of drywall screws into thebutt block 40 along the center axis 56 and then sliding the butt block40 behind one of the drywall sheets 12, 14 until these temporarily setdrywall screws abut the edge of the drywall sheets 12, 14.

[0025] As FIG. 3 shows, a first series of drywall screws 60 are used tosecure the first flange 42 of the butt block 40 to a portion of thefirst drywall sheet 12 that is located some distance from the buttinterface 16. Immediately thereafter, a second series of drywall screws62 are similarly driven into the second drywall sheet 14 to secure acorresponding portion of the sheet 14 to the second flange 44 of thebutt block 40. These actions cause the first and second surfaces 46, 48that are described in reference to FIG. 2 to be drawn tightly againstinterior surfaces 68, 70 of the respective sheets 12, 14.

[0026] At this point in time, the exterior surfaces 64, 66 of therespective drywall sheets 12, 14 are substantially aligned with eachother in substantially the same plane as the rest of the drywall sheets12, 14, much in the manner as is shown in the conventional joint that isdepicted in FIG. 1.

[0027] Referring now to FIG. 4, the preferred embodiment of theinvention further includes steps of driving a third series of screws 74into portions of the first drywall sheet to 12 that are fairly close tothe butt interface 16. At about the same time, a fourth series of screws76 are driven into portions of the second drywall sheet 14 that arefairly close to the butt interface 16. As the screws 74, 76 aretightened, the area of the drywall sheets 12, 14 that are adjacent tothe butt interface 16 are drawn into the recess 72 that is defined bythe recess defining structure 50 in the butt block 40, thereby creatinga secondary recess 78 to be formed on the exterior surface of the joint.In other words, the exterior surfaces 64, 66 of the drywall sheets 12,14 become pitched inwardly toward the butt interface 16, as is clearlyshown in FIG. 4.

[0028] Looking now to FIG. 5, the secondary recess 78 that is shown inFIG. 4 will now be filled by a process that includes applying anadhesive mesh joint tape that is of conventional construction over thebutt interface 16, and then applying a joint compound 82 to fill therest of the secondary recess 78. This is preferably performed so thatthe resulting joint 86 has a planar exterior surface that lies withinthe same plane 84 as the main portions of the first and second sheets12, 14 of drywall.

[0029] It is to be understood, however, that even though numerouscharacteristics and advantages of the present invention have been setforth in the foregoing description, together with details of thestructure and function of the invention, the disclosure is illustrativeonly, and changes may be made in detail, especially in matters of shape,size and arrangement of parts within the principles of the invention tothe full extent indicated by the broad general meaning of the terms inwhich the appended claims are expressed.

What is claimed is:
 1. A method of making a drywall joint, comprisingsteps of: (a) positioning a butt block that has a-recessed surface on aninterior side of a joint that is to be formed between a first drywallsheet and a second drywall sheet; (b) securing at least one of the firstand second drywall sheets to the butt block so that the secured sheet ismade to conform in shape to the recessed surface, thereby forming asecondary recess on an exterior of the drywall sheet in the area atwhich the joint is to be made; and (c) applying joint compound withinthe secondary recess.
 2. A method of making a drywall joint according toclaim 1, wherein step (b) is further performed by securing both thefirst and second sheets to the recessed surface, whereby the secondaryrecess is formed on an exterior of both of the drywall sheets in thearea at which the joint is to be made.
 3. A method of making a drywalljoint according to claim 2, wherein step (b) is further performed bysecuring first portions of the respective sheets to the butt block, andthen securing second portions of the sheets, which are closer to thearea at which the joint is to be made than the first portions, to thebutt block, thereby gradually pulling the sheets against the recessedsurface to form the secondary recess.
 4. A method of making a drywalljoint according to claim 1, wherein step (b) is further performed bysecuring a first portion of the sheet to be secured the butt block, andthen securing a second portion of the sheet to the butt block that iscloser to the area at which the joint is to be made than the firstportion, thereby gradually pulling the sheet against the recessedsurface to form the secondary recess.
 5. A method of making a drywalljoint according to claim 1, wherein step (c) is performed so as tocomplete a joint that is substantially planar on an exterior surfacethereof.
 6. A butt block for forming a drywall joint, comprising: afirst surface for engaging a first sheet of drywall; a second surfacefor engaging a second sheet of drywall; and recess defining means fordefining a recessed area between said first and second surfaces, saidrecess defining means being constructed and arranged to be drawn intocontact with butt edge areas of the first and second sheets of drywallwhen fully secured to said sheets of drywall, whereby the butt edgeareas will be caused to form a concave secondary recess on an exteriorsurface of the drywall joint.
 7. A butt block according to claim 6,wherein said butt block is fabricated from a material that may bepenetrated by a drywall screw and that will provide sufficient anchoringfor the drywall screw for the drywall screw to be able to pull the buttedge area of a sheet of drywall against the recessed area.
 8. A buttblock according to claim 7, wherein said butt block is fabricated from amaterial comprising fiberglass.
 9. A butt block according to claim 6,wherein said butt block further comprises first and second outboardflange members, and wherein said first and second surfaces are defined,respectively, on said first and second outboard flange members.
 10. Adrywall joint, comprising: a first sheet of drywall having a first buttedge; a second sheet of drywall having a second butt edge, said firstand second sheets of drywall being positioned so that said first buttedge is adjacent to said second butt edge at a butt interface; recessforming means engaging said first and second sheets for pulling saidfirst and second butt edges inwardly so as to define a secondary recessin exterior surfaces of the first and second sheets in the area of thebutt interface; and a sealant applied in said secondary recess.
 11. Adrywall joint according to claim 10, wherein said sealant comprises asolidified joint compound.
 12. A drywall joint according to claim 10,wherein said sealant is applied so that an outer surface of said sealantis positioned substantially within a common plane with exterior surfacesof said first and second sheets of drywall that are not affected by saidrecess forming means.
 13. A drywall joint according to claim 10, whereinsaid recess forming means comprises a butt block comprising a firstsurface for engaging the first sheet of drywall; a second surface forengaging the second sheet of drywall; and a recess defining meansdefining a recessed area between said first and second surfaces, saidrecess defining means being constructed and arranged to be drawn intocontact with butt edge areas of the first and second sheets of drywallwhen fully secured to said sheets of drywall, whereby the butt edgeareas will be caused to form a concave secondary recess on an exteriorsurface of the drywall joint.